The Wave W10

WAVE Systems Inc is dedicated to addressing one of the leading causes of accidental death, drowning. WAVE is a wireless swimmer tracking system that is the first solution with the affordability, simplicity and reliability to enable widespread adoption. The system empowers swimmers everywhere to be monitored and prevent drownings from occurring.

Injection Molding Cast Study – The WAVE W10

Product: Real-time drowning detection system

Project: Deliver 100 sets of high standard appearance watertight speaking containers

Issue: Parts were found to be loose during pre-production assembly

Results: Manufactured 100 sets of durable high quality containers ready for the next summer waves

Learn more below…

Project Summary

HLH first worked with WAVE in mid-2020 on the W20 project. This time, WAVE was back to collaborate on their latest W10 device, knowing they would receive quality solutions and high quality production parts.

The Challenges and Solution

During the assembly stage, we found the case to be very loose. Loose part designs are desirable for certain products but not for the W10 (a portable device designed to be used as often as one swims).



Due to the demand for a high-quality appearance, HLH needed to look for a solution that would create a more robust product with as little as possible change to the exterior appearance. After several reviews with our engineering and manufacturing teams, several solutions were proposed. It was decided the best choice was to add extra material into the handle loop cavity, then further add holes to the front housing and pegs to the back accordingly.

The Results and Takeaway

Through this solution, the parts were assembled tightly ensuring durability whilst maintaining the device’s high standard appearance and light-weight portability. “We went into this project with HLH expecting that refinements and improvements would be needed, and are happy with the results” said Dave Cutler, WAVE’s CEO.

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